Glass Stack Structure for Flexible Display Bubble Management
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Solution Overview
Problem
The manufacturing process of ultra-thin glass (UTG) for flexible display devices faces challenges due to the thin thickness of the glass, leading to durability issues and defects caused by bubble adhesion between mother glasses and the carrier plate, resulting in defective UTG packs with reduced flatness and increased breaks.
Innovation Solution
A glass stack structure with high viscous wave lines perpendicular to the bubble discharge flow is used to prevent reverse bubble flow and enlarge the effective cell area, employing a carrier plate with high viscous adhesive lines and a low viscous adhesive layer to ensure proper adhesion and bubble removal during the laminating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a plurality of mother glasses is stacked on a carrier plate to form a glass stack structure, then the durability during handling is improved, but bubbles may remain between the mother glasses and carrier plate causing adhesion defects
Solution Approach 1:
The adhesive region is segmented into a first adhesive line with high viscosity at the periphery and a second adhesive line with low viscosity in the interior. This segmentation allows the high viscosity peripheral adhesive to prevent bubble reverse flow while the low viscosity interior adhesive ensures complete bubble removal and proper adhesion.
Solution Approach 2:
Different regions of the adhesive structure are given different local qualities: the peripheral first adhesive line has high viscosity to act as a barrier against bubble reverse flow, while the interior second adhesive line has low viscosity to facilitate bubble discharge and ensure thorough adhesion. This local differentiation resolves the contradiction between preventing reverse flow and ensuring complete adhesion.
2Productivity
If the cell area is enlarged to improve manufacturing efficiency, then productivity increases, but bubble reverse flow may occur reducing adhesion quality
Solution Approach 1:
The adhesive structure is segmented into peripheral high viscosity adhesive lines and interior low viscosity adhesive regions. This segmentation allows the cell area to be enlarged for higher productivity while the high viscosity peripheral adhesive prevents bubble reverse flow, maintaining adhesion quality.
Solution Approach 2:
The high viscosity first adhesive line is placed at the periphery to preliminarily prevent bubble reverse flow before the low viscosity second adhesive line completes the adhesion process. This preliminary anti-action allows larger cell areas to be used without compromising adhesion quality.
3Reliability
If high viscous adhesive is used to prevent bubble reverse flow, then adhesion quality improves, but bubble removal becomes difficult
Solution Approach 1:
The adhesive system is segmented into two distinct adhesive lines with different viscosity characteristics. The high viscosity first adhesive line prevents bubble reverse flow while the low viscosity second adhesive line facilitates easy bubble removal, resolving the contradiction between adhesion quality and ease of manufacture.
Solution Approach 2:
Different local qualities of adhesive viscosity are applied: high viscosity at the periphery for preventing reverse flow and low viscosity in the interior for easy bubble removal. This local quality differentiation simultaneously achieves both adhesion quality and ease of manufacture.
4Adaptability or versatility
If the thickness of UTG is reduced to improve flexibility, then adaptability increases, but durability deteriorates requiring special handling
Solution Approach 1:
Multiple thin mother glasses are merged into a stacked structure and adhered to a carrier plate. This merging allows individual thin UTG layers to maintain their flexibility while the combined stack structure provides enhanced durability and enables special handling techniques during manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively prevents bubble reverse flow and maximizes the effective cell area, improving the adherence and reducing defects in the UTG packs, thereby enhancing the durability and flatness of the glass stack structure.
Implementation Method 1
a plurality of adhesive lines including a high viscous material and arranged at peripheral portions of the carrier plate and the mother glasses
Implementation Method 2
the carrier plate and the mother glasses are adhered to each other at the peripheral portions by the adhesive lines
Data Source
AI summary
A glass stack structure includes: a carrier plate having a width in a first direction and a length in a second direction; a stack glass on the carrier plate and including mother glasses sequentially stacked therein; adhesive lines including a high viscous material and arranged at peripheral portions of the carrier plate and the mother glasses to adhere the carrier plate to the mother glasses, and the adhesive lines includes wave lines extending in the second direction and spaced apart from each other in the first direction and linear lines extending in the first direction and spaced apart from each other in the second direction; and an adhesive layer including a low viscous material and covering a cell area of the carrier plate and the mother glasses to adhere the carrier plate to the mother glasses, where the cell area is defined by the wave lines and the linear lines.